Automated manufacturing system

ABSTRACT

The method of fabricating printed circuit terminal interconnection assemblies including the steps of (a) reading manifestations from a record medium indicative of predetermined terminal interconnections to be formed between designated terminals in a coordinate array; (b) providing signals ordered according to a predetermined system indicative of ordered terminal interconnections in response to the manifestation so read and staring said signals; (c) reading the stored signals and generating terminal interconnection numerical control parameters defining nonintersecting printed circuit paths to be formed on a predetermined coordinate terminal array; and (d) recording the numerical control parameters on a record medium for use in the control of the operation of a numerically controlled reproduction apparatus.

United States Patent [72] Inventors Jerry L. Nam 3,308,438 3/l967 Spergel et 8]. 1 1 340/l72.5 St. Paul; 3,325,786 6/1967 Shashoua et a1. .1 340/1725 Harold J. Lindee, Minneapolis; Edwa d F, 3,124,784 3/1964 Schaaf et a1. 340/173 Melin, St. Paul, John H. Pemberton, St. $286,083 1 1/1966 Nielsen H 235/6 I .l 1 Paul, Clarence C, Piflenger, St, Paul Park, 3,308,438 3/1967 Spergel 6! 8|. 340/1715 and William M. Swanson, St. Paul, Minn. 3,325,786 6/1967 Shashoua et al. 340/1725 [21] PP 422'682 Primary Examiner-Eugene G. Botz f ted 2 33 7 1 Attorneys-Thomas J. Nikolai and John P. Dority a en ar. [73] Assignee Sperry Rand Corporation 1 New York, N.Y.

ABSTRACT: The method of fabricating printed circuit ter- 54 AUTOMATED MANUFACTURING SYSTEM mina l interconnect ion assemblies includingthe O f readlng manifestations from a recond medlum indicative of 12 Claims, 53 Drawing Figs.

predetermlned terminal interconnections to be formed [52] U.S. Cl 235/l5l.l, between designated tel-minds in a coordinate UL) 96/271 340/1725 providing signals ordered according to a predetermined [51] Int. Cl ..G06f 15/46, system indicative f ordered ex-mind interconnections in [50] Field I 253 122 1 response to the manifestation so read and staring said signals; swell i (c.) reading the stroed signals and generating terminal inter (lnqulred); 96/271 (lnqmred) connection numeriealcontrol parameters defining nonintersecting printed circuit paths to be formed on a predetermined [56] References Cited coordinate terminal array; and (d.) recordin g the numerical UNITED STATES PATENTS control parameters on a record medium for use in the control 3,124,784 3/1964 Schaaf et a1. 340/173 of the operation of a numerically controlled reproduction ap- 3,286,083 11/1966 Nielsen 235161.11 paratus.

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SHEET 01 OF 22 IO l4 I8 IE 26 3O IE INPUT- GENERAL 23 34 MFG. -v OUTPUT PURPOSE b ROUT'NG -b DATA FOR CONTROL PROCESS ASSEMBLY EQUIPMENT COMPUTER DATA MASTER RECORD 22 32s WIRED ASSEMBLY wmms DATA OP cone U-ADDRESS V-ADDRESS s-sns ns-ans lS-BITS ism--330 i29 -i|s i|4 io F 1g. 3 a

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PATENTEDIIAR 2l97I 3.567.914

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PATENTEU MAR 2197i SEIEU C6 SF 22 PATENIEDIIIII 2m: 3.567.914

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PATENTEU MAR 2 I971 SHEET 12 OF 22 mEE UUUEEEEDDUiW --NIOIO PATENTED m 219m DEFINE TERMINAL CONNECTIONS TO BE MADE GENERATE PRINTED CIRCUIT TERMINAL- CONNECTION ROUTES ASSIGN PRINTED CIRCUIT CONDUCTORS T0 LAYER AND CHASSIS I ave DRAW THE PRINTED CIRCUIT TERMINAL- CONNECTION CONDUCTORS FOR EACH CHASSIS LAYER PHOTOGRAPH COMPOSITE OF TERMINAL OVERLAY AND EACH CHASSIS LAYER DRAWING Fig. 18

DEFINE TERMINAL CONNECTIONS TO BE MADE EVALUATE SELECTED CHASSIS TABS AND SORT IN A PREOETERMINED MANNER GENERATE PRINTED CIRCUIT TERMINAL- CONNECTION ROUTES FOR ONE LAYER f 586 w 594 EVALUATE nourzo TERMINAL-CONNECTIONS ACCORING TO PREDETERMINED CRITERIA f 592 TEST ROUTED TERMINAL-CONNECTIONS zgggg FOR LAYER TERMINALS I ACCEPTABLE DRAW TERMINAL CONNECTIONS FOR ONE LAYER OR STOETE ROUTES FOR '1 PHOTOGRAPH (IMPOSITE OF TERMINAL ARRAY AND EACH CHASSIS LAYER DRAWING TO PRINTED CIRCUIT PROCESS Fig. /9

PATENTEIJIIIII 2I9TI 3567.914

SL-IZU 1 CF 22 EXECUTIVE 6|0 AND UTILITY CONTROL GIZ SM I INITAL CHAASSIS WIRE TAB FILE SEL cTIou ND PRELIMINARY 6I6 m- ORDERING OF MAINTENANCE TABS Isom'n [GIG RE-EVALUATE mo SORT 7 CHASSIS TABS [626 (soR'r III Fig. ROUTE cIIAssIs mas AND 630 7 I EVALUATE 622 ROUTES PLQT TERMINAL cormccnous To mum} F o 29 7 FOR LAYERS CIRCUIT 632 or CHASSIS PROCESS REFERENCE 634 CORNER o I zlshlslsl |64I65 .h E

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INDICATE "sELEcT RouTINE -STOP- ENTER DESIRED CONTROL cooEs sTART- INTERPRET CALL CODE cooE= soRT ENTRY CODE: "END" SEARCH LIBRARY FOR DESIGNATED ROUTINE LOAD DESIGNATED ROUTINE EXECUTE DESIGNATED ROUTINE SHEET LOAD "ROUTER" CONTROL I INDICATE SELECT soRT' STOP- ENTER oEsIREo soRT CALL cooE START- ERROR INDICATION INTERPRET CALL CODE FIRST TIME LOAD "RouTER" ExEcuTE "ROUTER" RETURN CONTROL EXECUTIVE CONTROL ROUTINE Fig. 2/

"SORT I" THROUGH TAB RouTINE FILE No 720 I 724 LOAD "sum 1 E E AN0"RouTER" SORT I ROUTINES SORT II REMAINDER OF TABS ROUTE ONE CHASSIS LAYER CHASSIS COMPLETELY ROUTED PATENTEI] m 21971 READ WIRE TAB FILE TITLE, RECORD TITLE ON CHASSIS WIRE TAB FILE PREPARE STORAGE SELECT BAY AND CHASSIS INDICATE SELECT soar PARAMETERS STOP MAKE SELECTION OF SORT PARAMETERS START READ WIRE TABS FROM MASTER FILE I ?54 SELECT WIRE TAB ENTRIES FOR SELECTED CHASSIS AND RECORD ON CHASSIS WIRE TAB FILE I ?56 FORM WEIGHT WORD FOR EACH TERMINAL CONNECTION ACCORDING TO THE SELECTED SORT PARAMETERS MASTER WIRE TAB FILE COMPLETELY PROCESSED? NUMERICALLY SORT CHASSIS TERMINAL CONNECTIONS ACCORDING TO WEIGHT WORD VALUES RECORD SORTED LIST OF WIRE TABS FOR ROUTING SHEET 16 [IF 22 SORT I Fig. 22

PROCESS TITLE, FILE NUMBER FROM CHASSIS ROUTER MAGNETIC TAPE READ ROUTE WORDS FROM MIT. FOR LAYER OONVERT PACKED ROUTE WORDS TO PLOTTER CONTROL FORMAT RECORD PLOTTER CONTROL ITEMS ON RECORD MEDIUM LAYER COMPLETED? 962-- YES END OF CHASSIS FILE START NEW LAYER REGDRD 965 YES PLOTTER ROUTINE PATENTEUMAR 21971 3557,511

sum 17UF 22 04 I I I o\ 0| (4) 01 07 05 OIO 09 06 0;- mo 06 D9 02 e) 08: D8 03 03 I 02 SEE LEGEND ON NEXT SHEET PATENIEI] IIIR 21 SHEET 1 8 IIF OOI OIO IOO LEGENDZ QAD OUADRANT, ANGLE, DISTANCE 000 NO SORT BEND POINT DISTANCE TO CENTER ANGLE FROM VERTICAL OF ORIGIN T0 DESTINATION QUADRANT OF ORIGIN AND DESTINATION OUADRANT AND ANGLE OUADRANT AND DISTANCE ANGLE AND QUADRANT DISTANCE AND QUADRANT ANGLE AND DISTANCE DISTANCE AND ANGLE Fig. 24

PATENTEUHAR 2m 3567.914

SHEET 19 [1F 22 770 START /772 INDICATE "SELECT SORT PARAMETERS" STOP TT4 SELECT SORT PARAMETERS sTART /776 (XcYc) READ TERMINAL- CONNECTONS FROM SORTED LIST STORED BY SORT I 778 CALCULATE AI [|80(AAi 1] ASAi CALCULATE A2 [l802|AiAU STORE WE'GHT VALUE CHASSIS TERMINAL- CONNECTIONS ALL CONSIDERED 794 YES 796 CHASSIS TERMINAL- CONNECTIONS ACCORDING TO WEIGHT WORDS AND STORE 798 SORT 11 

1. The method of fabricating printed circuit terminal interconnection assemblies including the steps of: a. reading manifestations from a record medium indicative of predetermined terminal interconnections to be formed between designated terminals in a coordinate array; b. providing signals ordered according to a predetermined system indicative of ordered terminal interconnections in response to the manifestation so read and storing said signals; c. Reading the stored signals and generating terminal interconnection numerical control parameters defining nonintersecting printed circuit paths to be formed on a predetermined coordinate terminal array; and d. recording the numerical control parameters on a record medium for use in the control of the operation of a numerically controlled reproduction apparatus.
 2. A method of fabricating printed circuit terminal interconnection assemblies including the steps of: a. reading manifestations indicative of predetermined terminal interconnections to be formed between designated terminals in a coordinate array from a record medium; b. Providing signals ordered according to a predetermined system indicative of ordered terminal interconnections in response to the manifestations so read and storing said signals; c. reading the stored signals and generating terminal interconnection numerical control signals defining nonintersecting printed circuit paths to be formed on a predetermined coordinate terminal array; d. temporarily storing the numerical control signals; and e. drawing the master layout on a predetermined scale in response to the stored numerical control signals.
 3. A method of fabricating printed circuit terminal interconnection assemblies including the steps of: a. reading manifestations indicative of predetermined terminal interconnections to be formed between designated terminals in a coordinate array from a record medium; b. providing signals ordered according to a predetermined system indicative of ordered terminal interconnections in response to the manifestations so read storing said signals; c. reading the stored signals and generating terminal interconnection numerical control signals defining nonintersecting printed circuit paths to be formed on a predetermined coordinate terminal array; d. temporarily storing the numerical control signals; e. drawing the master layout on a predetermined scale in response to the stored numerical control signals; f. forming an overlay layout of the predetermined coordinate terminal array on a transparent backing material to the same scale as said master layout drawing; g. placing the transparent array over said drawing and aligning the drawing in a predetermined relationship therewith; and h. making a composite photograph of the aligned combination of the routed path drawing and the overlay for use in the printed circuit fabrication process.
 4. In a system for manufacturing multiplanar circuit module terminal-interconnection assemblies for use in a printed circuit fabrication, where each fabricated plane includes at least an insulating substrate member on which nonintersecting routed printed circuit paths are to be formed and having a plurality of holes arranged in a predetermined coordinate array drilled therethrough, with each hole having its surface plated-through with electrically conductive material, the fabricated planes stacked with respective holes aligned with predetermined one arranged for receiving conductive material therethrough in contact with the plated-through conductive material for providing interlayer electrical and physical coupling, a method for generating route-defining signals indicative of master routed printed circuit interterminal connection layouts for each plane, comprising the steps of: a. reading manifestations from a record medium indicative of predetermined origin-to-destination terminal connections to be formed by printed circuit paths; b. providing signals ordered according to a predetermined system indicative of respective ones of ordered terminal interconnections in response to the manifestations so read; c. storing the ordered signals; d. sequentially reading ones of said ordered signals relating to associated ones of the origin-to-destination terminals; e. generating route-defining signals for the origin-to-destination terminals so read for one of the planes, said route being nonintersecting with Previously generated routes on the plane, and storing said nonintersecting route-defining signals as they are generated for use in controlling the reproduction of the origin-to-destination routed paths; f. generating obstacle-avoiding route-defining signals for the origin-to-destination terminals found to intersect previously generated routes for the plane being prepared, when such a nonintersecting route can be provided, and storing said obstacle-avoiding route-defining signals as generated for use in controlling the reproduction of the obstacle-avoiding origin-to-destination paths; g. rejecting origin-to-destination terminals which cannot be provided a nonintersecting route on the plane being prepared; h. repeating steps d-g until all of the stored signals have been considered; i. advancing the plane level to be prepared and repeating steps d-h for the nonrouted origin-to-destination terminals which can be routed thereon; and j. repeating steps d-i until all origin-to-destination terminals have been routed on one of said planes.
 5. The method of claim 4 wherein the step of generating route-defining signals for the origin-to-destination terminals includes the steps of: a. selecting a beginning direction on the coordinate array for the prospective route; b. determining a bend point indicative of a preferred coordinate route-defining path based on the selected beginning direction and the coordinate position of the origin terminal and the destination terminal; and c. rejecting the preferred route when it is found to intersect a previously established route.
 6. In a system for manufacturing multiplanar circuit module terminal-interconnection assemblies for use in a printed circuit fabrication, where each fabricated plane includes at least an insulating substrate member on which nonintersecting routed printed circuit paths are to be formed and having a plurality of holes arranged in a predetermined coordinate array drilled therethrough, with each hole having its surface plated-through with electrically conductive material, the fabricated planes stacked with respective holes aligned with predetermined ones arranged for receiving conductive material therethrough in contact with the plated-through conductive material for providing interlayer electrical and physical coupling, a method for generating master routed printed circuit interterminal connection layouts for each plane, comprising the steps of: a. reading manifestations from a record medium indicative of predetermined origin-to-destination terminal connections to be formed by printed circuit paths; b. providing signals ordered according to a predetermined system indicative of respective ones of ordered terminal interconnections in response to the manifestations so read; c. storing the ordered signals; d. sequentially reading ones of said ordered signals relating to associated ones of the origin-to-destination terminals; e. generating route-defining signals for the origin-to-destination terminals so read for one of the planes, said route being nonintersecting with previously generated routes on the plane, and storing said nonintersecting route-defining signals as they are generated; f. generating obstacle-avoiding route-defining signals for the origin-to-destination terminals found to intersect previously generated routes for the plane being prepared, when such a nonintersecting route can be provided, and storing said obstacle-avoiding route-defining signals as generated; g. rejecting origin-to-destination terminals which cannot be provided a nonintersecting route on the plane being prepared; h. repeating steps d-g until all of the stored signals have been considered; i. advancing the plane level to be prepared and repeating steps d-h for the nonrouted origin-to-destination terminals which can be routed thereon; j. repeating steps d-i until All origin-to-destination terminals have been routed on one of said planes; and k. applying the route-defining signals to a numerically controlled plotting apparatus and drawing the master layout on a predetermined scale for each of the planes so prepared in response to the applied route-defining signals.
 7. The method of claim 6 wherein the step of generating route-defining signals for the origin-to-destination terminals includes the steps of: a. selecting a beginning direction on the coordinate array for the prospective route; b. determining a bend point indicative of a preferred coordinate route-defining path based on the selected beginning direction and the coordinate position of the origin terminal and the destination terminal; and c. rejecting the preferred route when it is found to intersect a previously established route.
 8. In a system for manufacturing multiplanar circuit module terminal-interconnection assemblies for use in a printed circuit fabrication, where each fabricated plane includes at least an insulating substrate member on which nonintersecting routed printed circuit paths are to be formed and having a plurality of holes arranged in a predetermined coordinate array drilled therethrough, with each hole having its surface plated-through with electrically conductive material, the fabricated planes stacked with respective holes aligned with predetermined one arranged for receiving conductive material therethrough in contact with the plated-through conductive material for providing interlayer electrical and physical coupling, a method for generating master routed printed circuit interterminal connection layouts composite photographs for each plane for use in the printed circuit fabrication process, comprising the steps of: a. reading manifestations from a record medium indicative of predetermined origin-to-destination terminal connections to be formed by printed circuit paths; b. providing signals ordered according to a predetermined system indicative of respective ones of ordered terminal interconnections in response to the manifestations so read; c. storing the ordered signals; d. sequentially reading ones of said ordered signals relating to associated ones of the origin-to-destination terminals; e. generating route-defining signals for the origin-to-destination terminals so read for one of the planes, said route being nonintersecting with previously generated routes on the plane, and storing said nonintersecting route-defining signals as they are generated; f. generating obstacle-avoiding route-defining signals for the origin-to-destination terminals found to intersect previously generated routes for the plane being prepared, when such a nonintersecting route can be provided, and storing said obstacle-avoiding route-defining signals as generated; g. rejecting origin-to-destination terminals which cannot be provided a nonintersecting route on the plane being prepared; h. repeating steps d-g until all of the stored signals have been considered; i. advancing the plane level to be prepared and repeating steps d-h for the nonrouted origin-to-destination terminals which can be routed thereon; j. repeating steps d-i until all origin-to-destination terminals have been routed on one of said planes; k. applying the route-defining signals to a numerically controlled plotting apparatus and drawing the master layout on a predetermined scale for each of the planes so prepared in response to the applied route-defining signals; l. forming an overlay layout of the predetermined coordinate terminal array on a transparent backing material to the same scale as said master layout drawings; m. sequentially placing the transparent array over each of said drawings and aligning the respective drawings in a predetermined relationship therewith; and n. photographing the aligned combination of the routed path drawings and the overlay to form the mastEr routed layout for each plane for use in the printed circuit fabrication process.
 9. The method of claim 8 wherein the step of generating route-defining signals for the origin-to-destination terminals includes the steps of: a. selecting a beginning direction on the coordinate array for the prospective route; b. determining a bend point indicative of a preferred coordinate route-defining path based on the selected beginning direction and the coordinate position of the origin terminal and the destination terminal; and c. rejecting the preferred route when it is found to intersect a previously established route.
 10. In a system for manufacturing multiplanar circuit module terminal-interconnection assemblies for use in a printed circuit fabrication, where each fabricated plane includes at least an insulating substrate member on which nonintersecting routed printed circuit paths are to be formed and having a plurality of holes arranged in a predetermined coordinate array drilled therethrough, with each hole having its surface plated-through with electrically conductive material, the fabricated planes stacked with respective holes aligned with predetermined ones arranged for receiving conductive material therethrough in contact with the plated-through conductive material for providing interlayer electrical and physical coupling, a method for generating master routed printed circuit interterminal connection layouts for each plane, for use in the printed circuit fabrication process, including the steps of: a. reading manifestations from a record medium indicative of predetermined origin-to-destination terminal connections to be formed by printed circuit paths for a selected chassis; b. providing signals ordered according to a predetermined system indicative of respective ones of ordered terminal interconnections in response to the manifestations so read; c. storing the ordered signals; d. selecting a predetermined number of planes for the chassis interconnections; e. establishing an image storage table with a discrete location for each routable area on the coordinate array for storing signals indicative of the direction of a routed path passing through the locations; f. sequentially reading ones of said ordered signals relating to associated ones of the origin-to-destination terminals; g. selecting a beginning direction on the coordinate array for the prospective route; h. determining a bend point indicative of a preferred coordinate route-defining path based on the selected beginning direction and the coordinate position of the origin terminal and the destination terminal; i. rejecting a preferred route found to intersect a routable area already utilized by a previously established route, as determined by signals stored in said image table; j. storing an acceptable route in associated locations in said image table; k. generating obstacle-avoiding route-defining signals for the origin-to-destination terminals found to intersect previously generated routes for the plane being prepared, when such a nonintersecting route can be provided, and storing said obstacle-avoiding route-defining signals, as generated, in the image table locations associated with said route; l. rejecting origin-to-destination terminals which cannot be provided a nonintersecting route on the plane being prepared; m. repeating steps f-1 until all of the stored signals have been considered; n. advancing the plane level to be prepared and repeating steps e-m for the nonrouted origin-to-destination terminals which can be routed thereon; o. terminating the routing process where the predetermined number of planes have been processed; and p. indicating the number, if any, of the origin-to-destination terminals remaining unrouted.
 11. In a system for manufacturing multiplanar circuit module terminal-interconnection assemblies for use in a printed circuit fabrication, where each fabricated plaNe includes at least an insulating substrate member on which nonintersecting routed printed circuit paths are to be formed and having a plurality of holes arranged in a predetermined coordinate array drilled therethrough, with each hole having its surface plated-through with electrically conductive material, the fabricated planes stacked with respective holes aligned with predetermined ones arranged for receiving conductive material therethrough in contact with the plated-through conductive material for providing interlayer electrical and physical coupling, a method for generating master routed printed circuit interterminal connection layout drawings for each plane, for use in the printed circuit fabrication process, including the steps of: a. reading manifestations from a record medium indicative of predetermined origin-to-destination terminal connections to be formed by printed circuit paths for a selected chassis; b. providing signals ordered according to a predetermined system indicative of respective ones of ordered terminal interconnections in response to the manifestations so read; c. storing the ordered signals; d. selecting a predetermined number of planes for the chassis interconnections; e. establishing an image storage table with a discrete location for each routable area on the coordinate array for storing signals indicative of the direction of a routed path passing through the locations; f. sequentially reading ones of said ordered signals relating to associated ones of the origin-to-destination terminals; g. selecting a beginning direction on the coordinate array for the prospective route; h. determining a bend point indicative of a preferred coordinate route-defining path based on the selected beginning direction and the coordinate position of the origin terminal and the destination terminal; i. rejecting a preferred route found to intersect a routable area already utilized by a previously established route, as determined by signals stored in said image table; j. storing an acceptable route in associated locations in said image table; k. generating obstacle-avoiding route-defining signals for the origin-to-destination terminals found to intersect previously generated routes for the plane being prepared, when such a nonintersecting route can be provided, and storing said obstacle-avoiding route-defining signals as generated, in the image table location associated with said route;
 12. In a system for manufacturing multiplanar circuit module terminal-interconnection assemblies for use in a printed circuit fabrication, where each fabricated plane includes at least an insulating substrate member on which nonintersecting routed printed circuit paths are to be formed and having a plurality of holes arranged in a predetermined coordinate array drilled therethrough, with each hole having its surface plated-through with electrically conductive material, the fabricated planes stacked with respective holes aligned with predetermined ones arranged for receiving conductive material therethrough in contact wiTh the plated-through conductive material for providing interlayer electrical and physical coupling, a method for generating master routed printed circuit interterminal connection layout composite photographs for each plane, for use in the printed circuit fabrication process, comprising the steps of: a. reading manifestations from a record medium indicative of predetermined origin-to-destination terminal connections to be formed by printed circuit paths for a selected chassis; b. providing signals ordered according to a predetermined system indicative of respective ones of ordered terminal interconnections in response to the manifestations so read; c. storing the ordered signals; d. selecting a predetermined number of planes for the chassis interconnections; e. establishing an image storage table with a discrete location for each routable area on the coordinate array for storing signals indicative of the direction of a routed path passing through the locations; f. sequentially reading ones of said ordered signals relating to associated ones of the origin-to-destination terminals; g. selecting a beginning direction on the coordinate array for the prospective route; h. determining a bend point indicative of a preferred coordinate route-defining path based on the selected beginning direction and the coordinate position of the origin terminal and the destination terminal; i. rejecting a preferred route found to intersect a routable area already utilized by a previously established route, as determined by signals stored in said image table; j. storing an acceptable route in associated locations in said image table; k. generating obstacle-avoiding route-defining signals for the origin-to-destination terminals found to intersect previously generated routes for the plane being prepared, when such a nonintersecting route can be provided, and storing said obstacle-avoiding route-defining signals, as generated, in the image table locations associated with said route; 